Aluminum and mercuric chloride catalyst composition and process



United States Patent 3,183,218 ALUMINUM AND MERCURIC CHLORIDE CATA- LYST COMPOSITION AND PROCESS Frank X. Werber, Rocltville, and Rajendra N. Chadha, Silver Spring, Md., assignors to W. R. Grace & Co., a corporation of Connecticut No Drawing. Filed May 21, 1963, Ser. No. 282,149

13 Claims. (CL 260-85.5)

This invention relates to a novel and useful polymerization catalyst and a process utilizing said catalyst.

Summarily this invention is directed to polymerizing vinyl monomers by subjecting said monomers to the action of a catalyst consisting essentially of the reaction products of aluminum and mercuric chloride. The term vinyl monomers herein means compounds of the formula wherein R is hydrogen or an organic radical and R is an organic radical. The vinyl monomers are wellknown in the art and include such material as acrylic acid esters, methacrylic acid esters, vinyl esters, vinyl nitriles, styrene and substituted styrenes. Among the suitable acrylic acid esters which may be employed in the present invention are: methyl acrylate; ethyl acrylate; n-propyl acrylate; isopropyl' acrylate; 'n butyl acrylate; isobutyl acrylate; sec-butyl acrylate; tert-butyl acrylate; n-pentyl acrylate; n-hexyl acrylate; 2-ethylbutyl acrylate; 2-ethylhexyl acrylate; n-heptyl acrylate; n-octyl acrylate; 3,5,5-trimethylhexyl acrylate; octadecyl acrylate; cyclopentyl acrylate; cyclohexyl acrylate; abitol acrylate (mixed isomers); n-decyl acrylate; tridecyl acrylate; 3,3,5-trimethylcyclohexyl acrylate; Z-n-butoxyethyl acrylate; 2-ethoxyethyl acrylate; 3-ethoxypropyl acrylate; S-methoxybutyl acrylate; 2-methoxyethyl acrylate; benzyl acrylate; Z-phenoxyethyl acrylate; phenyl acrylate; 2- phenylethyl acrylate; 2-bromoethyl acrylate; Z-chloroethoxyethyl acrylate; Z-chloroethyl acrylate; 2,2,2-trifluoroethyl acrylate; N,N-diethylaminoethyl acrylate; 1,1- dihydroheptafluorobutyl acrylate; N,N-dimethylaminoethyl acrylate; 2-N-morpholinoethyl acrylate and tetrahydrofurfuryl acrylate.

Other suitable vinyl monomers include: abitol methacrylate; acrylonitrile; allyl methacrylate; n-amyl methacrylate; iso-amyl methacrylate; benzyl methacrylate; Z-bromoethyl methacrylate; 2,2-butoxyethyl methacrylate; sec-butyl methacrylate; iso-butyl methacrylate; tert-butyl methacrylate; 2 -chloroethyl methacrylate; Z-chlorostyrene; S-chlorostyrene; 4-chlorostyrene; cinnamyl methacrylate; beta-cyanoethyl methacrylate; cyclohexyl methacrylate; cyclopentyl methacrylate; n-decyl methacrylate; 2,5-dichlorostyrene; N,N-diethylaminoethyl methacrylate; 1,1-dihydroheptafluorobutyl methacrylate; N,N-dimethlaminoethyl methacrylate; 2-ethoxyethy1 methacrylate; ethylene dimethacrylate; Z-ethylhexoxyethyl methacrylate; Z-ethylhexyl methacrylate; ethyl methaorylate; furfuryl methacrylate; n-heptyl methacrylate; n-hexyl methacryate; n-lauryl methacrylate; lauryl methacrylate; 3-methoxybutyl methacrylate; Z-methoxyethyl methacrrylate; methyl methacrylate; alpha-methylstyrene; octadecyl methac'rylate; iso-propyl methacrylate; styrene; tetraethyleneglycol dimeth-acrylate; 3,3,5-trimethylcyclohexyl met-hacrylate; 3,5,5-trimethylhexyl methacrylate; vinyl acetate; vinyl butyra-te; vinyl n-decanoate; vinyl 2- ethylhexoate; vinyl laurate; vinyl methacrylate; vinyl noctanoate; vinyl oleate; vinyl phenylacetate; vinyl propionate and vinyl stearate. The monomers may be used individually or in various combinations to form copolymers ice or interpolymers. Many others are known in the art and may likewise be used.

The polymerization reaction is operable under atmospheric conditions, i.e. in air but in some cases, notably polymerization of styrenes and substituted styrenes, the reaction is preferably performed in an inert oxygen-free The polymerization reaction is performed at tempera- 1 tures ranging from 20 C. up to the boiling point of the".

monomer being polymerized.

The catalyst components are operable in an Al:HgCl weight ratio range of 0.1 to 10:1 preferably a. 1:1 weight ratio is employed.

Since both catalyst components are normally solids, to obtain optimum reaction with the aluminum catalyst component, the HgCl is dissolved in a solvent. Various solvents are operable and are well known to one skilled in the ant. One class of solvents employed with good results is the ethers, e.g. diethyl ethyl. In some cases, for example when methyl methacrylate is the monomer to be polymerized, the monomer itself acts as a solvent for HgCl and no additional solvent is needed. Other vinyl monomers having a solvent action on the HgCl; can be found empirically by one skilled in the art. The weight ratio of HgCl, to monomer reactant is generally in the range 1:5 to or more, preferably about 1:25 to 40.

The catalyst components can be premixed prior to addition to the monomer or can be added to the monomer sequentially. No advantage is noted either way nor is there a preferred order of addition of the catalyst cornponents to the monomer.

The following examples will more fully explain but expressly not limit the scope of this invention.

EXAMPLE 1 3 g. of n-butyl acrylate, reagent grade, were washed with dilute NaOH, then with water until neutral. The washed monomer was dried over Na SO and passed through a silica gel column. The thus purified n-butyl acrylate was charged at 25 C. to an open test tube along with a catalyst consisting essentially of 0.5 g. of minus 30 mesh aluminum metal granules and 0.1 g. HgCl, dissolved in 2.0 cc. diethyl ether. After about 30 minutes, during which time the reaction temperature increased to about 30-40 C., a slight amount of swelling or growth appeared around the solid catalyst particles. This polymeric growth continued until after about 3 hours it filled the entire volume formerly occupied by the liquid. The

solid polymeric growth around the catalyst particles was soft and spongy. A sample of the polymer product was taken after 18 hours of reaction. The polymeric product was not soluble in boiling acetone. Another sample of the product showed that the polymer product dissolves readily in an isopropanol-HCI solution leaving a solid catalyst residue. On addition of a portion of the polymer containing isopropanol-HCI solution to water, a semisolid polybutyl acrylate precipitate of low molecular weight resulted.

EXAMPLE 2 Example 1 was repeated except that the 0.5 g. of aluminum was added in the form of foil strips instead of as.

granules. After standing for 18 hours at room tempera 4 ture (25 C.) the liquid converted to a clear soft gel. soluble polymer. After standing at room temperature for The gel is separated from the foil mechanically. The gel one hour, the methyl ketone solution formed a thick gel. dissolves readily in hot HCl-isopropanol. This gel did not dissolve upon reheating at reflux for 15 The preceding procedures using both aluminum granules minutes. The mixture was filtered and the gel washed and aluminum foil were repeated except that the reacwell with MEK. The gel was dried overnight in vacuo tions were performed in a nitrogen flushed, 250 ml. filter at 40 C. The MEK filtrates were added to methanol to flask under nitrogen. The rates of reaction and the polyprecipitate the polymer. The precipitated polymer was mer products obtained were about the same. filtered, washed with methanol and dried at 40 C. in

vacuo overnight. The MEK soluble polymer product EXAMPLE 3 weighed 1.4 g. The weight average molecular weight of Example 1 was repeated except that 3 g of y acetate the MEK soluble polymer product was 42,000.

were substituted for the 3 8- 0f y aefylale- The Table I, following, shows various monomers and cata- P y y acetate P obtained was in the form of lyst weight ratios operable in the practice of the instant p y Particles which were insoluble in het acetate but invention. The procedure was the same as that used in dissolved readily in hot p p Example 5 unless otherwise noted. In examples where co- EXAMPLE 4 polymers were formed, the respective monomers were both added to the filter flask before the addition of the catalyst components. In the examples wherein the reaction is performed in a nitrogen atmosphere the flask Example 3 was repeated except that the 0.5 g. of aluminum was in the form of foil strips. The polyvinyl acetate product was a gel which was insoluble in hot acetone but readily soluble in hot HCl-isopropanol. Y flushed with dry nilrogen before the {eactants were introduced and the reaction was performed in a stoppered EXAMPLE 5 flask under a nitrogen blanket. All the examples were 14 g. of methyl methacrylate were washed with dilute run at room temperat and m pher NaOH, and water until neutral, followed by drying over 25 pressure unless otherwise noted.

Table I Catal st y MEK in- MEK Example Monomer or eo-monomer Reaction soluble gel soluble Remarks No. tgms.) Aluml- H5501: time (hrs) fraction traction 1mm (e s-0 (e s) (e (gms.)

3.0 MMA 5.0 0. 1 16 Hard solid pol eth lmethacrylate product. 14.0 MMA 0. 25 0.43 16 d 0 2.3 Mn of ME solub a iraction=25,000. 14.0 MMA 0.5 0. 43 10 d 0 3. 2 Mn oi MEK soluble frnction=27,000. 14.0 MMA 1. 0 0. 43 16 d 0 1. 7 Mn oi MEK soluble fractlon=27,000. 14.0 MMA 1. 5 0.43 16 d 0 1. 5 Mn 0 0! MEK soluble fraction=32,000. 14.0 MMA 2.0 0. 43 16 d O 1. 7 Mn of MEK soluble fraction=32,000, 14.0 MMA 2. 5 0. 43 16 d 0 2. 1 Mu oi MEK soluble iractlon=38,000. 14.0 MMA 0. 5 0. 43 I 16 1. 5 2. 0 M11 e of MEK soluble fractl0n=52,000. 14.0 MMA 1. 0 0. 43 i 16 1. 4 0. 5 Mn of MEK soluble fraction=48,000. 14.0 MMA 1. 5 0. 43 l 16 1. 8 0 Mn oi MEK soluble irnetion=a5,000. 14.0 MMA 2.0 0. 43 I 10 2. 2 0. 6 Mu of MEK soluble fractlon=46,000. 14.0 MM A 2. 5 0.43 I 16 1. 8 1. 1 Mn of MEK soluble fraction=40,000. 14.0 MMA 1. 0 I 0.43 16 1. 6 1. 0 7 0 MMA and 6 8 styrene 1. 0 0. 43 24 4. 2 0. 5 Gel fraction does not fuse at 270 C. MEK

soluble fraction softens at 110130 C. 7.0 MMA and 6.8 styrene 1.0 0. 43 I 24 4.2 2.0 Infrared showed band at 1720 ernr indieating presence of methyl methacrylate and band at 1610 em.- indicating presence of styrene in copolymer. 21 40.0 MMA and 38.6 styrene 3. 0 I 1. 0 I 84 21.7 8 9 22 18.8 MMA and 16.0 ucrylo- 0.5 0.43 168 1.8 Infrared showed sharp band at 2250 cm.- nitrile. indicating presence of oerylonltrlie and band at 1720 cm. indicating presence of methyl methacrylate in copolymer. 18.8 MMA 0.5 0 f 240 0 0 No polymer product obtained. 2 18.8 M044 0 0.43 I 160 0 0 Do. 25 13.6 styrene 1. 0 0.43 48 0. 9 Mn 11 of MEK soluble frnctlon=05,000. 26 1. 0 0. 43 24 6. 5 Mn b of MEK soluble fraction=74,000.

s Aluminum is mesh granules.

b 10 ee. diethyl ether used as solvent for HgCh. unless otherwise specified.

MMA=n1ethyl methacrylate monomer washed with NnOH then water until neutral. The purified MMA was dried over NazSOr and passed through a silica gel column.

d Product treated with methanol-H01 so that gel fraction becomes MEK soluble. m 4ggvigligfizr aumber average molecular weight of polymethacrylute measured in MEK at 25 C. by Method of J. BlschoiI and V. Desreux, J. Poly. Sci.

l Reaction performed in nitrogen atmosphere. I No ether. HgCh dissolved in MMA h Mn 2 number average molecular weight of styrene measured in p-chiorotoiuene at 25 C. by Method of W. R. Krlgbaum, D. K. Carpenter and B. Neuman, J. Phys. Chem, 62, 1586 (1958).

Na SO and passage through a silica gel column. The As can be seen from Table I, Examples 23 and 24, no thus purified methyl methacrylate was charged to a 250 polymerization occurs if both catalyst components are ml. filter flask followed by the addition of 0.5 g. of alu- 5 not present.

minum granules (minus 30 mesh) and 0.43 g. I-lgCl dis- The present invention is operable in a solution polymsolved in 10 cc. diethyl ether. The reaction was allowed erization as well as in bulk polymerizations. For examto stand for 16 hours at room temperature (25 C.) exple: in Examples 7-12, the amount of ether added to the posed to air. A solid polymer product was obtained reaction flask as a solvent for HgCl is sufficient to create around the solid catalyst. 7 a solution polymerization environment.

cc. methyl ethyl ketone (MEK) was added to the The polymers obtained by this invention can be used polymer solution and the mixture was heated at reflux in the same manner as those commercially available. The for 15 minutes. Most of the product went into solution. methyl methacrylate polymer is especially useful where The methyl ethyl ketonesolution was filtered while hot thermal stability is a requisite such as in metal-filled to remove the catalyst residue and a small amount of inpolymers used as heat insulators.

We claim:

1. A polymerization catalyst consisting essentially of aluminum and HgCI the weight ratio of AlzHgCl being in the range of 0.1 to :1 respectively.

2. The composition of claim 1 wherein the HgClis solubilized in an ether.

3. The composition of claim 2 wherein the ether is diethyl ether.

4. The process of polymerizing vinyl monomers of the group consisting of esters of acrylic acid, esters of methacrylic acid, vinyl esters, styrene and substituted styrenes which comprises polymerizing said vinyl monomers in the presence of a catalyst consisting essentially of aluminum and HgCl in a weight ratio of 0.1 to 10:1 respectively, the weight ratio of HgCl to the vinyl monomer group member being in the range 1:5 to 100 respectively.

5. The process according to claim 4 wherein the ester of methacrylic acid is methyl methacrylate.

6. The process according to claim 4 wherein the HgCl is solubilized in an ether.

7. The process according to claim 6 wherein the vinyl ester is vinyl acetate.

8. The process according to claim 6 wherein the ester of acrylic acid is butyl acrylate.

9. The process according to claim 6 wherein the polymerization reaction is performed in an inert oxygen-free atmosphere.

10. The processof copolymerizing methylmethacrylate and styrene which comprises copolymerizing methylmethacrylate and styrene in the presence of a catalsyet consisting essentially of aluminum and HgCl in a weight ratio of 0.1 to 10:1 respectively, the weight ratio of HgCl to monomer reactants being in the range of 1:5 to respectively.

11. The process according to claim 10 wherein the polymerization reaction is performed in an inert oxygenfree atmosphere.

12. The process of copolymerizing methylmethacrylate References Cited by the Examiner UNITED STATES PATENTS 2,686,775 8/54 Howard 26088.7 2,927,105 3/60 Nienburg et al 260-949 2,935,542 3/60 Minckler et al. 260-949 2,969,346 1/61 Coover et al. 260-935 JOSEPH L. SCHOFER, Primary Examiner.

DONALD E. CZAJA, Examiner. 

4. THE PROCESS OF POLYMERIZING VINYL MONOMERS OF THE GROUP CONSISTING OF ESTERS OF ACRYLIC ACID, ESTERS OF METHACRYLIC ACID, VINYL ESTERS, STYRENE AND SUBSTITUTED STYRENES WHICH COMPRISES POLYMERIZING SAID VINYL MONOMERS IN THE PRESENCE OF A CATALYST CONSISTING ESSENTIALLY OF ALUMINUM AND HGCL2 IN WEIGHT RATIO OF 0.1 TO 10:1 RESPECTIVELY, THE WEIGHT RATIO OF HGCL2 TO THE VINYL MONOMER GROUP MEMBER BEING IN THE RANGE 1:5 TO 100 RESPECTIVELY. 